Installation Manual - Freedom MCC
Instruction Booklet IM04302004EEffective September 2016Supersedes October 2010Freedom 2100 motor control centerinstallation and maintenance 14General information. . . . . . . . . . . . . . . . . . 2Receiving, handling, and storage . . . . . . . 4Installing control center sections . . . . . . . 5Installing conduit and wiring. . . . . . . . . . . 9Incoming line connections . . . . . . . . . . . . 11Overcurrent protection devices. . . . . . . . 14Overload relay heater selection. . . . . . . . 16Inspection prior to energizing. . . . . . . . . 19Unit installation and adjustment. . . . . . . 20Maintenance. . . . . . . . . . . . . . . . . . . . . . 22Plan views. . . . . . . . . . . . . . . . . . . . . . . . 27Related instructional leaflets. . . . . . . . . . 29Arc resistant LV MCC . . . . . . . . . . . . . . . 29Contacting Eaton. . . . . . . . . . . . . . . . . . . 31This electrical control equipment is designed to beinstalled, operated, and maintained by adequatelytrained workmen. These instructions do notcover all details, variations, or combinations ofthe equipment, its storage, delivery, installation,check-out, safe operation,or maintenance. Caremust be exercised to comply with local, state, andnational regulations, as well as safety practices,for this class of equipment. The maximum shortcircuit capability of the equipment should not beexceeded by connection to a source with highercapacity. If maintenance or troubleshootingassistance is required,contact your nearest Eatonsales office.
Instruction Booklet IM04302004EFreedom 2100 motor control center installation and maintenance manual Effective September 2016Part 1. General informationThe motor control centerThe Eaton Freedom 2100 motor control center may be joined toexisting Five Star, Series 2100, and Advantage installations usingthe splice bar kits common to both. Units designed for the Freedom2100 can be mounted in Five Star Series and Series 2100 sections,but the opposite is not recommended, because Five Star and Series2100 units may lack terminal blocks and sufficient interruptingcapacity. The Freedom 2100 MCC may be joined to existing EatonFreedom Unitrol and F10 Unitrol MCCs with a special splice bar kit,but units are not interchangableThe operating handle on the controller unit (3) moves vertically. In theON or TRIPPED positions,the handle interlocks with the unit door toprevent its opening. In this position, authorized personnel can openthe door by turning the defeater mechanism screw. (21) With theunit door open and the operating handle in the ON position, anotherinterlock to the divider pan prevents removal of the unit. This sameinterlock prevents insertion of the unit unless the handle mechanismis in the OFF position. To ensure that units are not energizedaccidentally or by unauthorized personnel, the handle mechanismcan be padlocked in the OFF position. Space for a minimum of threepadlocks is provided on each handle. The device panel (5) is mountedon the drawout unit. It will accommodate up to six pilot devices. Theoverload reset button is mounted on the unit door.Control center nomenclatureThe numbers shown in parentheses in the following text refer to theballoon legends in Figure 2.The Eaton Freedom 2100 motor control center consists of oneor more totally enclosed, dead front, free standing structuralassemblies 90 inches high which are compartmentalized to houseindividual control units. (2) With control units mounted in the frontside only, the structure may be 16 or 21 inches deep. For mountingunits back-to-back, the structure is 21 inches deep. Steel covers(7) enclose the structure at the top, sides and at the rear of frontmounted-only structures.A vertical bus system installed in each vertical section is connectedto the horizontal bus to feed the individual control units. The verticalbus is isolated by a full height barrier. (6) An optional labyrinth barrierprovides both isolation and insulation. An automatic shutter isincluded with the labyrinth barrier system to cover the stab openingsfor each control unit.At the top of each section, a door provides ready access to the tophorizontal wireway (11) and ground bus. The horizontal wirewayis isolated from the bus systems by steel barriers which can beremoved for installation and maintenance operations. Adequatespace is provided for control wiring and top cable entry.At the bottom of each section, a door (18) provides ready accessto the bottom horizontal wireway, and neutral bus (if provided). Thebottom of each section is completely open to provide unrestrictedbottom entry of cable and conduit .Channel sills may be installedacross the bottom of the control center if specified, and an optionalbottom plate may also be specified.A vertical wireway 8 inches deep, extending the full 90 inch height ofthe control center is located to the right of each unit compartment.This wireway is covered by two hinged doors (15) and contains cablesupports to secure wire bundle sand cables. The vertical wirewayjoins the horizontal wireway at the top and bottom to provideunobstructed space for interwiring.Each vertical section provides space to mount up to six controllerunits (2) with a minimum height of 12 inches, in increments of sixinches, for a total of 72 inches of usable space. Controllers throughNEMAT Size 5 are drawout type (except reduced-voltage starters).These drawout unit assemblies are a completely self-containedpackage consisting of a steel enclosure, operating handle andelectrical components. The drawout assembly slides into thiscompartment on guide rails (11) to provide easy withdrawal andreinsertion and to ensure precise alignment of the unit stabs withthe vertical bus. Each drawout unit is held in place by a singlequarter-turn latch (4) which can only been gaged when the unit stabsare fully mated with the vertical bus. Each unit has a separate door,(1) held closed by a minimum of two quarter-turn fasteners.2EATON www.eaton.comFigure 1. NameplateRatingsEach Freedom 2100 motor control center has a rating nameplateattached to the door of the top horizontal wireway of the primarysection. See Figure 1 and Figure 2. This nameplate shows thegeneral order number under which the motor control center wasbuilt and its continuous electrical ratings, in terms of incoming linevoltage, phases, and frequency, and ampere ratings of the horizontalbus and the vertical bus for each section. In addition, this nameplateshows the passive short-circuit (withstand) rating of the horizontaland vertical bus system. The active short-circuit (interrupting) ratingsof the main and unit short-circuit protective devices are shown onlabels attached to the inside of each unit. Before installing a motorcontrol center, calculate and record the fault current available at theincoming line terminals. Verify that the short-circuit with standardshort-circuit interrupting ratings of the units in the motor controlcenter are appropriate for the fault current available.Qualified personnelIndividuals who install, operate, or maintain MCCs must be trainedand authorized to operate the equipment associated with theinstallation and maintenance of an MCC, as well as the operation ofthe equipment that receives its power from controller units in theMCC. Such individuals must be trained in the proper procedureswith respect to disconnecting and locking OFF power to the MCCand wearing personal protective equipment, which includes arcflash, insulating, and shielding materials, and also use insulatedtools and test equipment, following established safety proceduresas outlined in the National Electrical Safety Code (ANSI C2) andElectrical Equipment Maintenance (NFPA 70E).
Instruction Booklet IM04302004EFreedom 2100 motor control center installation and maintenance manual Effective September 2016 (7)Top and sidecovers(6)Vertical bus barrier—labyrinth (optional)(5)Device paneland devices(4)Quarterturn latch(3)Operatinghandle(1)Unit door(2)Drawoutunit(21)Defeatermechanism screw(15)Verticalwirewaydoor(18)Bottomwireway doorFigure 2. Motor control center nomenclatureEATON www.eaton.com3
Instruction Booklet IM04302004EFreedom 2100 motor control center installation and maintenance manual Effective September 2016Part 2. Receiving, handling, and storagem WARNINGMCC—HEAVY EQUIPMENT STATEMENTTHIS MCC CAN WEIGH IN EXCESS OF 2,000 POUNDS. REFER TO SHIPPINGMANIFESTS FOR EXACT WEIGHT OF EQUIPMENT. TO PREVENT SERIOUSINJURY OR DEATH, OR EQUIPMENT DAMAGE, FROM UNINTENDEDMOVEMENT OF EQUIPMENT DURING TRANSPORT, INSTALLATION ORANY OTHER OPERATIONS, ENSURE THAT (1) ONLY MATERIAL HANDLINGEQUIPMENT OF ADEQUATE CAPACITY AND RATING FOR THE LOADINVOLVED IS USED; (2) ONLY QUALIFIED PERSONNEL ARE INVOLVED;AND (3) ALL LIFTING/BRACING SHIPPING LABELS AND MARKINGSINSTRUCTIONS SHIPPED WITH THE MCC MUST BE FOLLOWED.ReceivingBefore and after unloading the motor control center, inspect eachsection and unit exterior for evidence of damage that may have beenincurred during shipment. If there is any indication that the controlcenter has been mishandled or shipped on its back or side, removethe drawout units and make a complete inspection of the internalstructure, bus bars, insulators, and unit components for possiblehidden damage. Report any damage found to the carrier at once.Overhead crane1. See Figure 3 for recommended lifting configuration.2. Select or adjust the rigging lengths to compensate for anyunequal weight distribution, and to maintain the motor controlcenter in an upright position.3. To reduce tension on the rigging and the compressive load onthe lifting angles, do not allow the angle between the liftingcables and vertical to exceed 45 degrees. Use slings with safetyhooks or shackles. Do not pass ropes or cables through liftingangle holes.Lift pointThe height of the liftpoint above thespreader should beat least 1/2 of “A”(the distance betweeneye bolts). Thisensures a maximumangle of 45º as shown.Max.45ºADon’t pass ropesor cablesthrough lift holes.Use slings withsafety hooksor shackles.Lift holeMOTOR CONTROL CENTERLift angleHandlingFigure 3. Correct use of lifting angleThe following guidelines are provided to help avoid personal injuryand equipment damage during handling, and to facilitate moving themotor control center at the job site.4. After removing the lifting angles, replace the mounting hardwareto prevent the entrance of dirt, etc.General hintsFork-lift truck1. Handle the motor control center with care to avoid damage tocomponents and to the enclosure or its paint finish.Motor control centers are normally top and front heavy. Balance theload carefully, and steady, as necessary, while moving. Always use asafety strap when handling with a fork-lift.2. Keep the motor control center in an upright position.3. Ensure that the moving means has the capacity to handle theweight of the motor control center.4. The control center should remain secured to the shipping skiduntil the motor control center is in its final location.5. Exercise care during any movement and placement operationsto prevent falling or unintentional rolling or tipping.6. Lifting angles for handling by overhead crane are bolted to thetop of each shipping section. Handling by overhead crane ispreferable, but when crane facilities are not available, the motorcontrol center can be positioned with a fork-lift truck or by usingrollers under the shipping skid.4EATON www.eaton.comRollersRod or pipe rollers, with the aid of pinch bars, provide a simplemethod of moving the motor control center on one floor level, ifthere is no significant incline. Roll the motor control center slowly,and steady the load to prevent tipping.StorageWhen an motor control center cannot be installed and placed intooperation immediately upon receipt, take steps to prevent damageby condensation or harsh environmental conditions. If the motorcontrol center cannot be installed in its final location, store it in aclean, dry, ventilated building, heated to prevent condensation, andprotected from dirt, dust, water, and mechanical damage. Whenstorage conditions are less than ideal, install temporary electricalheating, typically in the form of light bulbs, totaling 150 watts persection, hung in the vertical wireway, or by applying power toself-contained space heaters that the motor control center may beequipped with. Remove all loose packing and flammable materialsbefore energizing any of the heating elements.
Instruction Booklet IM04302004EFreedom 2100 motor control center installation and maintenance manual Effective September 2016 Part 3. Installing control center sectionsGeneralFreedom FlashGardE motor control centers (MCCs) are designedfor installation in accordance with both the National Electrical CodeT(NECT), NFPA 70, and the National Electrical Safety Code (NESC),ANSI C2.m CAUTIONIF WORK IS INVOLVED IN CONNECTING THE CONTROL CENTERWITH EXISTING EQUIPMENT, ENSURE THAT INCOMING POWER ISDISCONNECTED BEFORE WORK BEGINS. DISCONNECTING MEANSSHOULD BE LOCKED OUT AND/OR TAGGED OUT OF SERVICE. WHEREIT IS NOT FEASIBLE TO DE-ENERGIZE THE SYSTEM, THE FOLLOWINGPRECAUTIONS SHOULD BE TAKEN:A. Persons working near exposed parts that are or may beenergized should be instructed and should use practices(including appropriate personal protective equipment, whichincludes arc flash, insulating, and shielding materials, andinsulated tools and test equipment in accordance with theNFPA 70E).4. For bottom entry, position the MCC so that the conduit stubsor floor openings are located in the shaded areas shown on theMCC floor plan drawings (refer to page 27 and page 28for floor plan dimensions). The shaded areas represent the openspace available for conduit entry through the bottom of eachsection. A shaded area may be restricted if large controllers orauto-transformers are mounted in the bottom of the sections. Ifoptional bottom plates are supplied, the plates may be removedand drilled for conduit entry.5. Install the MCC in its final position, progressively leveling eachsection and bolting the frames together if they are separated.If necessary, secure the MCC to walls or other supportingsurfaces. Do not depend on wooden plugs driven into holes inmasonry, concrete, plaster, or similar materials. See NEC 110.13.6. If two or more shipping sections are to be joined into an integralassembly or a shipping section is to be joined to an existingsection, refer to paragraphs below before proceeding with theinstallation.7.Ground and bond the MCC as follows:a. MCCs used as service equipment for a grounded systemor as an incoming line section for a separately derived,previously grounded system:B. Persons working on exposed parts that are or may be energizedshould, in addition, be qualified persons who have been trainedto work on energized circuits.1. Run a grounding electrode conductor (ground wire)having a size in accordance with NEC 250.94 from thegrounding electrode to the MCC ground bus or groundterminal provided. See also NEC 250.92(A) and 92(B).Installation2. If the system is grounded at any point ahead of theMCC, the grounded conductor must be run to the MCCin accordance with NEC 250, and connected to theground bus terminal.1. Before any installation work begins, consult all drawingsfurnished by Eaton, as well as all applicable contract drawingsfor the installation. Give particular attention to the physicallocation of units in the control center and their relation to existingor planned conduit, busways, etc. Provide for future conduitentrance prior to control center installation.2. Locate the control center in the area shown on the building floorplans. If in a wet location or outside of the building, protect thecontrol center from water entering or accumulation within theenclosure. Recommended clearances or working spaces areas follows:a. Clearance from walls (where not rear accessible)—a minimum of 1/2 inch for indoor and 6 inches for outdooror wet locations.b. Clearance from front of MCC (working space)—minimumof 3 feet for control centers without exposed live parts.See NEC 110.13.c. For arc resistant MCCs up to 2500 A horizontal bus, there areno restrictions on the clearance above the MCC top plate.Standard Freedom MCC rules apply for conduit, cable trays,and wiring.NNote: This working space should not be used for storage and shouldhave adequate lighting.3. Since MCCs are assembled at the factory on smooth and levelsurfaces to ensure correct alignment of all parts, MCCs shouldbe securely mounted on a level surface. The foundation furnishedby the purchaser must be true and level, or the bottom framesmust be shimmed to support the entire base in a true plane. It isrecommended that leveled channel sills under both the front andrear of the control center be used to provide this level base. Drilland tap the channel sills for mounting bolts in accordance withthe applicable floor plan drawing and then either install the MCClevel with, or on top of, the finished floor. If sills are grouted inconcrete, the mounting bolts should be screwed in place andremain until the concrete has hardened.3. Do not make any connections to ground on the load sideof any neutral disconnecting line or any sensor usedfor ground-fault protection. Do not connect outgoinggrounding conductors to the neutral.b. MCCs used as service equipment for an ungrounded systemor as an incoming line section for a separately derived,previously ungrounded system:1. Run a grounding electrode conductor (ground wire)having a size in accordance with NEC 250.94 from thegrounding electrode to the MCC ground bus terminal.See NEC 250.92(A) and 92(B).c. MCCs not used as service equipment nor as an incoming linesection for a separately derived system, and used on either agrounded or ungrounded system:1. Ground the MCC ground bus by means of equipmentgrounding conductors having a size in accordance withNEC 250.95 or by bonding to the raceway enclosingthe main supply conductors in accordance withNEC 250.92(B).8. When all wiring and adjustments are complete, close all unit andwireway doors.9. In damp indoor locations, shield the MCC to prevent moistureand water from entering and accumulating.10. Unless the MCC has been designed for unusual serviceconditions, it should not be located where it will be exposedto ambient temperatures above 40 C (104 F), corrosive orexplosive fumes, dust, vapors, dripping or standing water,abnormal vibration, shock, or tilting.EATON www.eaton.com5
Instruction Booklet IM04302004EFreedom 2100 motor control center installation and maintenance manual Effective September 2016Joining compatible sectionsIf two more shipping sections are to be joined into an integralassembly, or a section added to an existing installation, splicing ofhorizontal bus, ground bus, neutral bus, and joining of the adjacentvertical sections must be planned with the installation.1. Remove the side sheets from adjacent vertical sections to bejoined. (These sheets will have been removed from factoryassembled sections.)2. The horizontal bus splice plates and connection hardware will beshipped with the MCC attached to one end of shipping section.Refer to Figure 4.3. This method provides the most convenient access to the bolts,and eliminates the need to remove the horizontal bus barriers inthat structure. Should the existing bus be oxidized, sand lightlywith a fine aluminum oxide paper.m CAUTIONDO NOT USE EMERY CLOTH OR ANY ABRASIVE CONTAINING METAL.4. Remove the upper horizontal wireway door from the structureon the right side of the left-hand (LH) section, and remove thetwo-piece wireway barrier to provide access to the ends of thebus in that section.Figure 4. Splice plates attached to right-hand section5. Move the section into place, aligning the upright structuralchannels and bottom channels. Alignment of the sectio
movement of equipment during transport, installation or any other operations, ensure that (1) only material handling equipment of adequate capacity and rating for the load involved is used; (2) only qualified personnel are involved; and (3) all lifting/bracing shipping labels and markin
October 2007 MCC-SVU02A-EN Models Cooling Only MCC 518 ZB MCC 524 ZB MCC 530 ZB MCC 536 ZB MCC 048 ZB Split System, 18,000 - 48,000 Btu/h Underceiling Type MCC Series 50 Hz. . anything with your air conditioning system. About this Manual Cautions appear at appropriate places in this instruction manual. Your personal safety and the proper
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